How to Remove a Broken Bolt: A Little Faith, a Few Prayers, and Some Battle-Tested Tools #bolt

Professional Methods for Removing Broken Bolts

Introduction

Broken bolts are a common and challenging issue in mechanical and industrial repairs. They often occur due to rust, excessive torque, or improper tool usage. Removing a broken bolt requires patience, precision, and sometimes creative approaches. Below are 14 effective and practical techniques to safely extract broken bolts under various circumstances.
14 Reliable Techniques to Remove Broken Bolts

1) Bolt Extractor Tools
Specialized tools designed to bite into the broken bolt and turn it out counterclockwise.
2) Left-Hand Drill Bits
Drilling with a left-handed bit can sometimes unscrew the bolt as it drills into it.
3) Center Drilling and Using an Extractor
Drill a small pilot hole in the center of the broken bolt, then insert an extractor tool to remove it.
4) Welding a Nut onto the Bolt Head
Weld a nut onto the exposed bolt stub, then use a wrench to back it out.
5) Applying Heat with a Torch or Industrial Soldering Iron
Heating causes metal expansion and breaks rust or corrosion bonds, easing removal.
6) Locking Pliers (Vise Grips)
If any portion of the bolt is exposed, locking pliers provide a firm grip to turn it out.
7)Controlled Tapping with a Hammer and Punch
Applying vibrations can break rust and free the bolt.
8) Cutting a Slot and Using a Flathead Screwdriver
Create a groove on the bolt head to insert a flathead screwdriver and turn it.
9) Using Penetrating Oils (e.g., WD-40)
Lubricates threads and reduces friction before applying extraction force.
10) Pneumatic and Hydraulic Tools
Powerful tools that can provide the necessary torque to remove stubborn bolts.
11) Applying Cold (Dry Ice or Freeze Spray)
Rapid contraction after heating may loosen the bolt by shrinking the metal.
12) Electrolysis for Rusted Bolts
A specialized method for dissolving corrosion in professional workshops.
13) Field Tricks

* Using epoxy with Allen wrenches
* Adding pipe extensions for extra leverage
* Employing rubber straps for increased grip

14) Wire EDM (Electrical Discharge Machining) – Advanced Precision Method
A high-precision, non-contact technique that uses electrical discharges to cut the bolt without damaging surrounding material. Ideal for costly or delicate components.
Final Notes

Before attempting removal, assess the bolt’s condition and how much is exposed. Always use penetrating oil and proceed patiently. Combining techniques and applying creativity often yields the best results. To prevent future bolt breakage, use proper torque settings and lubrication during installation.
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Видео How to Remove a Broken Bolt: A Little Faith, a Few Prayers, and Some Battle-Tested Tools #bolt канала Vahid Rahnama